Design files for this project can be found here
Update 11/1/2017 – Updated design to revision C with better toolpaths
Another project on the Tormach P770: milling the Portal Companion Cube out of both 6061 aluminum and 316 stainless steel. Ended up breaking a few endmills as this was my first time milling stainless steel on the Tormach, but otherwise no major issues were encountered.
The initial cube was made using an old model from a few years ago so it only took ~12 hours or so to generate the toolpaths, square the stock, and machine the cube. The cube was then cleaned up with some oxalic acid and a brass brush. The model used here was originally created in Inventor without using parametric modeling, so changing individual features was significantly harder than it should have been.
The model had some slight changes made to it in the second revision, but the main goal was to convert everything to a fully parametric model in Fusion360 to make it easier to resize and change individual features of the cube. Two individual cubes were made, a 2″ version out of 6061 aluminum and another 1.5″ version out of 316 stainless steel.
Improvements for this revision mainly involve the the toolpaths, with a focus on minimizing overlap to improve results when rotating/machining adjacent sides of the cube. Model parameters were also tweaked to allow for use of standard angle chamfer endmills in place of a ball mill for higher quality surface finishes on the draft faces. Three different chamfer endmills of 45°, 35°, and 22.5° are required.